Compositions for compounding, extrusion and melt processing of foamable and cellular halogen-free polymers

Abstract

Described herein are foamable compositions and methods of making foamed compositions. The foamable composition comprises at least one polymer and a foaming agent. The foaming agent comprises a talc or a talc derivative. The polymers described herein comprise a substantially non-halogenated polymer. One or more additives are added to render the compositions flame retardant and/or smoke suppressant. Also described are Power over Ethernet (PoE) cables, having at least one electrical conduit comprising an electrically conductive core, an insulation that at least partially surrounds said electrically conductive core and a polymeric separator extending from a proximal end to a distal end and having at least one channel adapted for receiving the at least one electrical conduit. The PoE cables are capable of carrying about 1 watt to about 200 watts of power.

What is claimed is: 
     
       1. A support-separator for use in a communications cable, the support separator comprising:
 a foamed polymeric preformed elongate body configured to extend from a proximal end to a distal end, the foamed polymeric elongate body comprising a plurality of channels each configured to receive a transmission medium configured to carry electrical power or telecommunication data, said foamed polymeric preformed elongate body further comprising a plurality of foamed cells, wherein each cell comprises a maximum diameter in range of about 0.0005 inches to about 0.003 inches; 
 wherein said foamed polymeric performed elongate body further comprises at least one base polymer selected from a group consisting of polyphenylenesulfide (PPS), polyetherimide (PEI), polysulfone (PSU), polypheylsulfone (PPSU), polyethersulfone (PES/PESU), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), polyetherketone (PEK), or polyolefins such as polyethylene (PE), polyproplylene (PP), cyclic olefin copolymer (COC), polycarbonate (PC), polyphenylene ether (PPE), liquid crystal polymer (LCP), or combinations thereof. 
 
     
     
       2. The support-separator of  claim 1 , wherein the transmission medium received by at least one of the plurality of channels comprises an electrical conductor and wherein the electrical conductor comprises a twisted pair of wires conductor. 
     
     
       3. The support-separator of  claim 2 , wherein the twisted pair of wires conductor is configured to carry about 10 watts to about 50 watts of electrical power. 
     
     
       4. The support-separator of  claim 2 , wherein each wire of the twisted pair of wires comprises an AWG in a range of about 22 to about 26. 
     
     
       5. The support-separator of  claim 1 , wherein the plurality of channels comprise at least five channels and the transmission medium received by each channel comprises one of an electrical conductor or an optical fiber cable. 
     
     
       6. The support-separator of  claim 5 , wherein the transmission medium received by each of at least four of the at least five channels comprises an electrical conductor and the transmission medium received by at least one of the at least five channels comprises an optical fiber cable. 
     
     
       7. The support-separator of  claim 6 , wherein the electrical conductor is configured to carry about 10 watts to about 50 watts of electrical power. 
     
     
       8. The support-separator of  claim 1 , further comprising a central channel configured to receive at least one of a fiber optic cable or a copper conductor. 
     
     
       9. The support-separator of  claim 1 , wherein said foamed polymeric preformed elongate body further comprises a plurality of electrically conductive elements distributed in said at least one base polymer. 
     
     
       10. The support-separator of  claim 9 , wherein said electrically conductive elements comprise a metal, a metal oxide, a carbon nanotube, a carbon fiber, a nickel coated carbon fiber, a single or a multi-wall graphene, a copper fiber, or a C 60  fullerene. 
     
     
       11. The support-separator of  claim 10 , wherein said metal comprises silver, aluminum, copper, gold, bronze, tin, zinc, iron, nickel, indium, gallium, stainless steel metal, or a combination thereof. 
     
     
       12. The support-separator of  claim 10 , wherein said metal oxide comprises copper oxide, bronze oxide, tin oxide, zinc oxide, zinc-doped indium oxide, indium tin oxide, nickel oxide, aluminum oxide, or a combination thereof. 
     
     
       13. The support-separator of  claim 9 , wherein a weight ratio of the electrically conductive elements to the at least one base polymer is in a range of about 1% to about 30%. 
     
     
       14. The support-separator of  claim 1 , wherein said foamed polymeric preformed elongate is configured to exhibit a foaming level in a range of about 20% to about 60%. 
     
     
       15. The support-separator of  claim 1 , wherein said foamed polymeric preformed elongate body comprises a tensile strength of about 2,500 psi to about 10,000 psi. 
     
     
       16. The support-separator of  claim 1 , wherein said foamed polymeric preformed elongate body comprises a specific gravity of about 1.10 to about 1.30. 
     
     
       17. The support-separator of  claim 1 , wherein the at least one base polymer comprises a substantially halogen-free polymer. 
     
     
       18. The support-separator of  claim 1 , wherein greater than 50% of said plurality of foamed cells exhibit a closed structure. 
     
     
       19. The support-separator of  claim 1 , wherein greater than 60% of said plurality of foamed cells exhibit a closed structure. 
     
     
       20. The support-separator of  claim 1 , wherein greater than 70% of said plurality of foamed cells exhibit a closed structure. 
     
     
       21. The support-separator of  claim 1 , wherein greater than 80% of said plurality of foamed cells exhibit a closed structure. 
     
     
       22. The support-separator of  claim 1 , wherein greater than 90% of said plurality of foamed cells exhibit a closed structure. 
     
     
       23. The support-separator of  claim 1 , further comprising a flame retardant additive distributed within said support-separator.